Case Study: a leading pharmaceutical manufacturer achieves faster IIoT rollout and major production savings with CloudRail

CloudRail highlights savings potential of up to 1.5 Million € per production site for a leading pharmaceutical manufacturer

CloudRail worked with a major pharmaceutical goods producer, one of the world’s largest pharma manufacturers, to improve condition monitoring and reduce downtime across highly automated production lines. The company faced inefficiencies in machine data acquisition across brownfield and greenfield environments, making it difficult to detect process deviations early and optimize key metrics like OEE, MTBF, and scrap rates.

CloudRail provided a Plug&Play industrial IoT setup using the CloudRail.Box edge gateway, IO-Link Master modules, and sensors, implemented with Bechtle IT. The initial pilot was completed in just 4 days and met strict pharmaceutical IT-security and compliance requirements. With CloudRail’s solution, one tablet line reduced scrap from about 20% to 8%, saving roughly €7,000 per day, and the broader rollout was projected to deliver around €50,000 in daily savings per site.